Absorbent composite article having fluid acquisition sub-layer

Abstract

An absorbent article has an absorbent core and a liquid permeable top sheet made of polyolefin material. An acquisition layer is provided between the top sheet and the core. The acquisition layer is a nonwoven fabric made from polyolefin fibers bonded by a cured resin. The acquisition layer has a larger pore size than the top sheet and is treated with a surface active agent to render it hydrophilic.

What is claimed is: 
     
       1. An absorbent article comprising a porous top sheet comprising a nonwoven polyolefin fabric, said top sheet having a basis weight of from about 10 to about 40 grams per square meter, an absorbent core, and a porous acquisition layer disposed between said top sheet and said core, said acquisition layer comprising a nonwoven fabric of polyolefin fibers an adhesive bonding said polyolefin fibers together, said acquisition layer having a basis weight of about 10 to about 100 grams per square meter, said acquisition layer having a pore size larger than the pore size of said top sheet and being treated with a surface active agent to render said acquisition layer hydrophilic, said top sheet and said acquisition layer being thermally bonded. 
     
     
       2. The absorbent article of claim 1 wherein the top sheet and the acquisition layer comprise the same polyolefin. 
     
     
       3. The absorbent article of claim 2 wherein said polyolefin is polypropylene. 
     
     
       4. The absorbent article of claim 1 wherein said top sheet is a nonwoven fabric of thermally bonded polyolefin fibers. 
     
     
       5. The absorbent article of claim 1 wherein said top sheet and acquisition layers are thermally bonded in spaced locations. 
     
     
       6. The absorbent article of claim 1 wherein said polyolefin fibers of said acquisition layer comprise bicomponent fibers. 
     
     
       7. The absorbent article of claim 1 wherein said polyolefin fibers of said top sheet comprise bicomponent fibers. 
     
     
       8. The absorbent article of claim 1 wherein said top sheet comprises fibers having a diameter of from about 7 to about 12 microns, and said acquisition layer comprises fibers having a diameter of from about 10 to about 24 microns. 
     
     
       9. The absorbent article of claim 1 wherein said adhesive is present in the mount of from about 10 to about 30% based on the weight of the fibers. 
     
     
       10. The absorbent article of claim 9 wherein said adhesive comprises a styrene butadiene acrylic latex. 
     
     
       11. The absorbent article of claim 9 wherein said adhesive comprises ethylene vinyl acetate. 
     
     
       12. The absorbent article of claim 9 wherein said adhesive comprises ethylene acrylic acid. 
     
     
       13. The absorbent article of claim 1 wherein said surface active agent is a surfactant having a surface tension of less than 31 dyne/cm. 
     
     
       14. The absorbent article of claim 13 wherein said surfactant comprises sulfosuccinates and derivates thereof.